Apparatus and method for handling and opening a frangible container

ABSTRACT

An apparatus and method for handling and opening frangible containers containing substantially solid contents is described. The apparatus includes a cutter configured to sever an upper portion of a container from a lower portion the container. The apparatus further includes a holder for holding the lower portion of the container, and a gripping device for gripping the upper portion of the container as the container is severed by the cutter. The gripping device lifts the upper portion from the lower portion of the bottle such that any portion of the solid contents within the upper portion is discharged to the lower portion of container. The apparatus also can include a positioner for presenting the bottle to the cutter for cutting.

TECHNICAL FIELD

The invention relates to devices and methods for opening a frangible container to empty the container of its contents, and more particularly, to an apparatus and method for severing a first portion of a frangible container from a second portion of the container in a manner that substantially reduces the loss of at least a portion of the contents from the container.

BACKGROUND

Blood plasma is used as a raw material to produce a variety of blood components and other therapeutic materials such as serum albumin, anitihemophilic factor, fibrinogen, gamma globulin, and the like. In practice, blood plasma often is collected and stored in containers having a relatively small volume. For example, plasma can be stored in one-liter high-density polyethylene (HDPE) bottles. In order to preserve the plasma for future processing, the plastic bottles of plasma can be frozen and stored at subzero temperatures ranging between about −20° C. and about −35° C., for example. The frozen plasma forms a solid slug within a storage container.

Plasma processing facilities typically process plasma in large batches. For example, a typical processing facility can process about 3800-3900 liters of plasma in a single processing run. Accordingly, frozen plasma from a large number of small, individual containers like those discussed above must be pooled together before batch processing. In a typical plasma processing facility, the frozen bottles of plasma can be partially thawed by exposing the sealed bottles to air flow at a temperature of about 5° C. for several hours. The warmer air causes the frozen plasma to thaw along its outer surfaces (i.e., to “skin-thaw”), and to separate from the interior walls of the containers, though the bulk of the plasma slug remains frozen. Once the plasma containers are adequately skin-thawed, one end is severed from each bottle by a sharp blade, and the bottles are emptied into a plasma-pooling vessel. The opened bottles can be manually or automatically emptied into a pooling vessel, for example. Once pooled, the batch of plasma is fully thawed and delivered for further processing. The emptied plasma bottles are safely discarded.

Some of the plasma contained within the sealed bottles can be lost during the bottle opening and emptying process. In particular, when a top of a bottle is severed, any portion of the frozen plasma that is within the severed top portion or cap portion of a bottle may be lost as the severed cap portion and the frozen plasma therein falls away from the main portion of the bottle. In addition, a portion of the frozen or partially frozen plasma within the bottles may adhere to the sharp blade used to sever the top ends of the bottles from the lower portions of the bottles. That portion of the plasma that is adhered to the blade cannot be easily recovered, and is typically wasted. Though only a small portion of the total volume of plasma in a single bottle may be lost as the bottle is opened, the accumulation of wasted plasma in large bottle opening operations can be substantial.

Accordingly, there is a need for an improved process for pooling and thawing blood plasma that minimizes the amount of plasma that is wasted in the bottle opening process. In particular, there is a need for an improved apparatus and method for preventing frozen or partially frozen plasma that is retained within a severed cap portion of a bottle from being lost. In addition, there is a need for an improved apparatus and method that prevents frozen or partially frozen plasma from adhering to a blade as the blade severs the plasma bottles.

SUMMARY

The invention includes an apparatus for opening frangible bottles containing substantially solid contents. The apparatus includes at least one cutter operable to sever a first portion of a bottle from a second portion of the bottle. The apparatus further includes at least one a bottle holder operable to hold the second portion of the bottle as the first portion is severed from the second portion. The apparatus also includes a gripper operable to releasably grip the first portion, and to substantially maintain the position of the first portion relative to the second portion as the first portion is severed from the second portion. The gripper also is operable to separate the first portion from the second portion of the bottle after severing.

The invention also includes a device for separating substantially solid contents from a frangible container. The device includes a means for severing an upper portion of the container from a lower portion of the container. The device also includes a means for holding the lower portion of the container as the upper portion is severed from the lower portion. The device further includes a means for releasably gripping the upper portion such that the position of the upper portion relative to the lower portion is substantially maintained as the upper portion is severed from the lower portion. The device may also include means for lifting the upper portion from the lower portion of the container such that any of the solid contents within the upper portion is deposited onto or into the lower portion as the upper portion is lifted.

The invention also includes a method of emptying a bottle of substantially solid contents. The method includes positioning the bottle for severing a first portion of the plastic bottle from a second portion of the bottle. The method also includes holding the first portion relative to the second portion, and severing the first portion from the second portion, such that the position of the first portion relative to the second portion is substantially unchanged during severing. The method also may include separating the first portion from the second portion such that substantially all of the solid contents remains with the second portion, and then discharging the contents from the second portion of the bottle.

The invention further includes a container handling apparatus. A first plate includes a plurality of spaced first jaw members, and a second plate includes a plurality of spaced second jaw members. The second plate is slidably disposed on the first plate. At least one support member pivotally connects the first plate to a frame, and is operable to permit the first plate to selectively move between a raised position and a lowered position. A first actuator is operable to selectively move the first plate between the raised position and the lowered position, and a second actuator is operable to selectively move the second plate relative to the first plate between a clamping position and a release position. Each of the first jaw members cooperates with one of the second jaw members to selectively grip a portion of a container when the first and second plates are in the clamping position, and to selectively release a portion of a container when the first and second plates are in the release position.

These and other aspects of the invention are described in detail in the following description and the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of a bottle opening apparatus according to the invention;

FIG. 2 is a perspective view of a bottle gripping device portion of the bottle opening apparatus shown in FIG. 1;

FIG. 3 is an exploded perspective view of the bottle-gripping device shown in FIG. 2;

FIGS. 4A-4F are a series of elevation views showing sequential operation of the bottle opening apparatus of FIG. 1;

FIGS. 5A-5B are plan views of a portion of the bottle gripping device respectively showing the device in a gripping position and a release position; and

FIG. 6 is a perspective view of a typical plastic transport and storage bottle for blood plasma.

DETAILED DESCRIPTION

A typical plastic transport and storage bottle 70 for blood plasma is shown in FIG. 6. The bottle 70 has a generally cylindrical shape with a lower portion 74 and an upper end 76. The upper end includes an open neck portion 75 configured to receive a removable sealing cap 72. Blood plasma is deposited in the bottle 70 and is frozen to form a frozen plasma slug 90. The thin-walled bottle 70 is constructed of a suitable polymeric material such as high-density polyethylene (HDPE). The bottle 70 can have a volume of about one liter, for example. As shown in FIG. 1, the plasma 70 fills a majority of the bottle's volume to form an unfilled volume or air space 71 near the top end 76 of the bottle 70. The upper surface of the plasma slug 90 defines a fill line or a cut line 78.

FIG. 1 shows one embodiment of a bottle-opening device 10 according to the invention. In this embodiment, a plurality of bottles 70 containing frozen plasma or the like are supported by a plurality of spaced bottle holders 62. The bottle holders 62 are configured to securely hold the bottles 70 in an upright position. The bottle holders 62 may be disposed on a movable conveyor belt 60. As shown in FIG. 1, the conveyor 60 selectively positions the bottles 70 between one or more cutting blades 80 and a bottle gripping apparatus 20. The blades 80 are mounted on movable supports 82 that are configured to advance the blades 80 toward and through the bottles 70, and to retract the blades 80 away from the severed bottles 70. Preferably, the frozen plasma within the bottles 70 is skin thawed before passing the blades 80 through the bottles 70.

Details of one embodiment of a bottle gripping apparatus 20 or “gripper” are shown in FIGS. 2 and 3. In this embodiment, the gripper 20 includes a plurality of pairs of moveable jaws 45, 47. Each pair of jaws 45, 47 is configured to selectively grip and release an upper portion 76 of a bottle 70. For example, each pair of jaws 45, 47 may be configured to cooperatively grip the neck or cap of a bottle 70. The jaws 45, 47 respectively project from a first sliding plate 44, and a second sliding plate 46. As shown in FIG. 3, the sliding plates 44, 46 include pluralities of elongated slots 52, 54. When aligned, the elongated slots 52, 54 receive shoulder bolts that extend through the slots 52, 54 and engage threaded holes 23 in a base plate 22. Washers 42 may be provided as shown on either side of the mated sliding plates 44, 46. The length of the shoulder bolts 49 is such that the sliding plates 44, 46 are sufficiently secured to the base plate 22, yet are substantially free to slide relative to each other via the elongated slots 52, 54.

As shown in FIG. 3, a first linear actuator 48 is disposed between a tab 41 on the first sliding plate 44, and a boss 43 on the second sliding plate 46. When the linear actuator 48 is contracted, the plates 44, 46 are caused to slide relative to each other such that each pair of cooperating jaws 45, 47 is urged together in a closed or gripping position (as shown in FIG. 5A). Conversely, when the linear actuator 48 is extended, the plates 44, 46 are caused to slide relative to each other such that each pair of cooperating jaws 45, 47 is urged apart to an open or release position (as shown in FIG. 5B). The first linear actuator 48 preferably is a double-acting air cylinder, such as a Bimba Model No. PC-092-DXP double-acting line cylinder having a 1.06 inch bore diameter and a 2-inch stroke, available from Bimba Manufacturing Company. Alternatively, another type of linear actuator such as a hydraulic cylinder, solenoid, or the like, may be used.

As shown in FIGS. 2 and 3, the base plate 22 includes a pair of spaced blocks that receive a shaft 26. The shaft 26 includes a keyway 27 on one end, and is tightly engaged in the blocks 24 such that the shaft 26 cannot rotate in the blocks 24. Each of a pair of opposed brackets 30 receives one end of the shaft for pivotally mounting the base plate 22 to a stationary frame (not shown) via fasteners 31. Bearings 32 may be provided to facilitate rotation of the shaft 26 in the brackets 30. A collar 34 may be removably mounted on each end of the shaft 26 to retain the shaft 26 and base plate 22 in the brackets 30. A pivot arm 36 is disposed on the end of the shaft 26 having the keyway 27, and is keyed to the shaft 26 by key 28. The distal end of the pivot arm 36 is rotatably connected to a yoke 38 by pin 37, and the yoke 38 is connected to one end of a second linear actuator 40. The opposite end of the second linear actuator 40 is pivotally connected to a stationary frame (not shown). The second linear actuator 40 preferably is a double-acting pneumatic cylinder, such as a Bimba Model No. PC-173-DXP double-acting line cylinder having a 1.5 inch bore diameter and a 3-inch stroke, available from Bimba Manufacturing Company. Alternatively, another type of linear actuator such as a hydraulic cylinder, solenoid, or the like, may be used.

Operation of the bottle opening apparatus 10 and the gripping device 20 is shown in FIGS. 4A-4F. As shown in FIG. 4A, a bottle 70 is supported in bottle holder 62 and is positioned proximate to the cutting blade 80 by conveyor 60. In FIG. 4A, the second linear actuator 40 is contracted, such that the pivot arm 36 downwardly rotates. The downward movement of the arm 36 causes the shaft 26 to rotate, thereby raising the sliding plates 44, 46 and gripping jaws 45, 47 to an elevated position. In this elevated position, the gripping apparatus 20 will not interfere with movement of bottles 70 carried by the bottle holders 62 and conveyor 60. As shown in FIG. 4B, with the bottle 70 at a desired location and the jaws 45, 47 of the gripper 20 in an open or release position (ref. FIG. 5B), the second linear actuator 40 is extended such that the pivot arm 36 causes the shaft 26 to rotate, thereby lowering the sliding plates 44, 46 and jaws 45, 47 to a lowered or gripping position. In this lowered position, when the first linear actuator 58 is contracted, a pair of jaws 45, 47 clamp around the upper portion of the bottle 70 (as shown in FIG. 1). Accordingly, the bottle 70 is securely supported by both the bottle holder 62 and the contracted jaws 45, 47.

As shown in FIG. 4C, the blade 80 is advanced toward and through the bottle by the movable blade support 82. As shown in FIG. 4D, the blade is then withdrawn from the severed bottle 70. The blade 80 severs the bottle 70 along a cut line 78 that divides the bottle into a lower portion 74 and an upper portion 76. Preferably, the cut line 78 substantially coincides with the bottom of the unfilled volume or air space 71 near the top end 76 of the bottle 70 (as shown in FIG. 6), such that substantially all of the contents of the bottle 70 is retained within the lower portion 74 of the bottle.

Nevertheless, as the blade 80 slices through the bottle 70 along cut line 78, at least some frozen or partially frozen plasma may remain in the upper portion 76. In addition, at least some of the frozen or partially frozen plasma may contact and adhere to the blade 80. As the blade 80 is withdrawn from the bottle 70, however, the top portion of the bottle 76 is held stationary by the jaws 45, 47 and the lower portion of the bottle 74 is held stationary by the bottle holder 62. Accordingly, the top portion 76 and bottom portion 74 act to scrape any adhered plasma from the blade 80 as the blade is withdrawn, and substantially prevent adhered plasma from being withdrawn from the severed bottle 70 as the blade 80 is withdrawn. Therefore, the bottle opening apparatus 10 substantially reduces loss of plasma from the bottle 70 as the bottle is severed.

As shown in FIG. 4E, once the bottle 70 has been severed into a lower portion 74 and an upper portion 76, the second linear actuator 40 is contracted, thereby raising the sliding plates 44, 46 and jaws 45, 47 to the elevated position. By gripping and lifting the upper portion of the bottle 76 in this manner, the gripping device 20 permits any plasma within the upper portion 76 to fall from the upper portion 76 such that the plasma is deposited and retained atop the lower portion of the bottle 74. Accordingly, the gripping device 20 acts to prevent any plasma within the upper portion 76 from being lost during the bottle opening process.

As shown in FIG. 4F, when the first linear actuator 48 is extended such that the jaws 45, 47 are in an open or release position (ref. FIG. 5B), the upper portion of the bottle 76 is released from the gripping apparatus 20. The lower portion of the bottle 74 and the plasma therein is carried away from the bottle opening apparatus 10 by the conveyor 60 for further processing.

The invention also includes a method of emptying substantially solid contents from a frangible container, such as from a thin-walled plastic bottle. With reference to FIGS. 4A-4F, the method includes positioning a container 70 for severing a first portion of the container 76 from a second portion of the container 74. As shown in FIG. 4A, the container 70 may be positioned proximate to a cutting blade 70 by a conveyor 60 or the like. As shown in FIG. 4B, the method also includes holding the first portion 76 relative to the second portion 74. For example, a holder 62 on a conveyor 60 may hold the second portion 74, and a moveable gripper 20 may hold the first portion 76. As shown in FIGS. 4C and 4D, the method further includes severing the first portion 76 from the second portion 74, such that the position of the first portion 76 relative to the second portion 74 is substantially unchanged during severing. After severing the container 70, the first portion 76 may be separated from the second portion 74 as shown in FIGS. 4E and 4F. As the first portion 76 is lifted from the second portion 74, any portion of the contents within the first portion 76 is permitted or caused to pass from the first portion 76 into or onto the underlying second portion 74. The contents then can be emptied from the second portion 74 of the container by any suitable manual or automated means.

The embodiments of the invention described above are provided to illustrate various aspects of the invention, and are not intended to limit the invention thereto. Persons of ordinary skill in the art will recognize that certain modifications can be made to the described embodiments without departing from the scope of the invention. For example, though the apparatus and method principally are described for removing frozen contents from a plastic bottle, a system and method according to the invention can also be applied to release frozen or solid contents from other types of frangible containers. For example, the invention can be used to release frozen or solid contents from a paper or cardboard carton or the like. All such modifications are intended to be within the scope of the appended claims. 

1. An apparatus for opening frangible bottles containing substantially solid contents, the apparatus comprising: (a) a cutter operable to sever a first portion of a bottle from a second portion of the bottle; (b) a bottle holder operable to hold the second portion of the bottle as the first portion is severed from the second portion; and (c) a gripper operable to releasably grip the first portion, and to substantially maintain the position of the first portion relative to the second portion as the first portion is severed from the second portion.
 2. An apparatus according to claim 1 wherein the cutter comprises a blade configured to slice the first portion from the second portion.
 3. An apparatus according to claim 1 wherein the cutter is operable to sever the bottle substantially coincident with a fill line that substantially corresponds to a margin of the solid contents.
 4. An apparatus according to claim 1 wherein the gripper includes a first jaw and an opposed second jaw, and wherein the first and second jaws are movable between a gripping position and a release position.
 5. An apparatus according to claim 1 further comprising a positioner operable to selectively position the bottle holder and the second portion of the bottle held therein relative to the cutter.
 6. An apparatus according to claim 5 wherein the positioner comprises a conveyor belt.
 7. An apparatus according to claim 1 wherein: (a) the cutter is operable to sever a plurality of first portions from a plurality of respective second portions of a plurality of bottles; (b) the bottle holder is operable to hold the second portions of the plurality of bottles as the first portions are severed from the second portions; and (c) the gripper is operable to releasably grip the first portions, and to substantially maintain the positions of the first portions relative to the respective second portions as the first portions are severed from the second portions.
 8. An apparatus according to claim 1 wherein the gripper is operable to separate the first portion from the second portion of the bottle after the first portion is severed from the second portion, such that any portion of the substantially frozen contents within the first portion is discharged from the first portion to the second portion.
 9. An apparatus according to claim 1 wherein the gripper comprises at least one pair of cooperating movable jaws.
 10. A apparatus for separating substantially solid contents from a frangible container, the device comprising: (a) means for severing an upper portion of the container from a lower portion of the container; (b) means for holding the lower portion of the container as the upper portion is severed from the lower portion; and (c) means for releasably gripping the upper portion such that the position of the upper portion relative to the lower portion is substantially maintained as the upper portion is severed from the lower portion.
 11. An apparatus according to claim 10 and further comprising means for selectively positioning the holding means relative to the cutting means.
 12. An apparatus according to claim 10 and further comprising means for separating the upper portion from the lower portion of the container after the upper portion is severed from the lower portion, the means for separating being operable to cause substantially any contents within the upper portion to be discharged to the lower portion as the portions are separated.
 13. An apparatus according to claim 10 wherein the means for severing comprises a blade operable to be passed between the first and second portions of the container.
 14. A method of emptying substantially solid contents from a frangible container, the method comprising: (a) positioning the container for severing a first portion of the container from a second portion of the container; (b) holding the first portion relative to the second portion, and severing the first portion from the second portion, such that the position of the first portion relative to the second portion is substantially unchanged during severing; and (c) discharging at least a portion of the contents from a portion of the container.
 15. A method according to claim 14 and further comprising removing the first portion from the second portion of the container after severing, and causing any portion of the contents within the first portion to be discharged onto or into the second portion.
 16. A method according to claim 14 wherein severing the first portion from the second portion comprises passing a blade through the container between the first and second portions.
 17. A method according to claim 16 wherein holding the first portion relative to the second portion substantially prevents any portion of the substantially solid contents from being removed from the container as the blade is passed between the first and second portions.
 18. A method according to claim 14 wherein the contents comprises a frozen liquid, and the method further comprises at least partially thawing the frozen liquid before severing the first portion from the second portion of the bottle.
 19. A method of opening a frangible container containing substantially frozen contents, the method comprising: (a) holding an upper portion and holding a lower portion of the container; (b) severing the upper portion from the lower portion as the upper and lower portions are held; (c) lifting the upper portion from the lower portion such that any contents within the upper portion are discharged into or onto the lower portion.
 20. An apparatus for opening a frangible container having a lower portion and an upper portion, the apparatus comprising: (a) a cutting blade; (b) a holder that holds the lower portion of the container and positions the container proximate to the cutting blade; and (c) a gripping device comprising: (i) a first jaw; (ii) a second jaw, the second jaw being moveable relative to the first jaw such that the second jaw and the first jaw are operable between an open position and a closed position; (iii) a pivot that permits the first and second jaws to pivot between a lowered position and a raised position; (iv) a first actuator that moves the first and second jaws between the lowered position and the raised position; and (v) a second actuator that moves the first and second jaws between the open position and the second position; wherein the gripping device is capable of selectively gripping the upper portion of the container as the container is severed between the upper and lower portions by the cutting blade, and is capable of lifting the upper portion from the lower portion after severing.
 21. A container handling apparatus comprising: (a) a first plate including a plurality of spaced first jaw members; (b) a second plate including a plurality of spaced second jaw members, the second plate being slidably disposed on the first plate; (c) at least one support member pivotally connecting the first plate to a frame, and operable to permit the first plate to selectively move between a raised position and a lowered position; (d) a first actuator operable to selectively move the first plate between the raised position and the lowered position; (e) a second actuator operable to selectively move the second plate relative to the first plate between a clamping position and a release position; (f) wherein each of the first jaw members cooperates with one of the second jaw members to selectively grip a portion of a container when the first and second plates are in the clamping position, and to selectively release a portion of the container when the first and second plates are in the release position.
 22. A container handling apparatus according to claim 21 wherein each of the first jaw members includes a first recess therein, each of the second jaw members includes a second recess therein, and wherein the first and second recesses cooperate to form a plurality of container receiving openings when the first and second plates are in the clamping position.
 23. A container handling apparatus according to claim 21 and further comprising a conveyor operable to selectively position a plurality of containers proximate to the first and second jaw members. 